Plug for patch systems

ABSTRACT

An improved plug is disclosed for use in a patch system in which plugs and receptacles are arranged in a high density fashion. The plugs can be formed individually or in gang fashion and are arranged to be positively latched in the associated receptacles. The plugs are polarized and include integral springs formed of the same plastics material as the plugs. The plugs can also be provided with a detent which allows the plugs to be mechanically held in the receptacles prior to making electrical engagement.

United States Patent 1191 Hoover [45] Aug. 26, 1975 1541 PLUG FOR PATCH SYSTEMS [75] Inventor:

[73] Assignee:

[22] Filed:

[21] Appl. No.:

Charles Donald Hoover, Harrisburg,

AMP Incorporated, Harrisburg, Pa.

Apr. s, 1974 Related U.S. Application Data [63] Continuation-impart of Ser. No. 419,167, Nov. 26,

1973. Pat. No. 3,874,763.

[52] U.S. Cl. 339/91 R; 339/184 M; 339/217 S [51] Int. C1.2 H01R 13/54 [58] Field of Search 339/91, 184, 186, 217

[56] References Cited UNITED STATES PATENTS 2,748,359 5/1956 Swan 339/184 M 3,004,235 10/1961 Cohen..... 339/186 M 3,409,858 ll/l968 Krehbicl 339/91 R 3,439,314 4/1969 Lightncr et al, 339/217 S 3,530,424 9/1970 Gregory 339/186 M 3,656,086 4/1972 Dcbaigt..... 339/186 M 3,670,289 6/1972 Bruner 339/186 R 3,699,502 10/1972 Carter 339/217 S 3,829,821 8/1974 Dcrr et al 339/91 R 3,842,388 10/1974 Harwood et al. 339/91 R Primary Examiner-Joseph H. McGlynn Attorney, Agent, 0r Firm- Russell J. Egan, Esq.

[ 5 7 ABSTRACT An improved plug is disclosed for use in a patch system in which plugs and receptacles are arranged in a high density fashion. The plugs can be formed individually or in gang fashion and are arranged to be positively latched in the associated receptacles. The plugs are polarized and include integral springs formed of the same plastics material as the plugs. The plugs can also be provided with a detent which allows the plugs to be mechanically held in the receptacles prior to making electrical engagement.

13 Claims, l0 Drawing Figures FATENTED M182 61975 salam 3 nf g1 PLUG FOR PATCH SYSTEMS CROSS REFERENCE TO RELATED APPLICATION The present application is a continuation-in-part of my application Ser. No. 419,167 filed Nov. 26, 1973, now U.S. Pat. No. 3,874,763.

BACKGROUND OF THE INVENTION l. The Field of the Invention The present invention relates to an improved plug for use in high density patch systems and in particular to a plug of plastics material utilizing the plastics material as a spring biased latching and retention means.

2. The lPrior Art ln high density pluggable patch systems there is an inherent problem in providing plugs which will suitably mate with the receptacles and yet can be readily removed for replacement and/or exchange purposes. The high density arrangement limits the amount of material that can be used in the plugs as well as to the number of configurations which can be used. It is clear that plugs for high density applications can not utilize extraneous springs or complicated latching arrangements since they would necessarily require a great amount of space which is not normally available.

Many attempts have been made to solve the above problem, however, most of them have relied upon the formation of the contact itself to give the necessary spring force for latching. While this may be suitable for some applications, it is not always possible since contacts with high spring forces may be subject t an unnecessary and unacceptable level of wear during normal usage.

There is a frequent requirement that plugs must have the capability of mechanically ixedly engaging the associated receptacle prior to electrical engagement of the contacts thereby. This feature is necessary when it is desired to run all the wires to a terminal board, for example, before actually cutting in the board to the associated circuitry. This has previously required the addition of expensive switching equipment, which is normally used only a very few times.

SUMMARY OF THE INVENTION The present invention is an improved plug for use in high density patch systems in which each receptacle has a polarized entrance. The plug is formed of a unitary piece of plastics material and has a polarized transverse section, a locking lance on one lateral side and a longitudinally extending resilient spring member on an opposite lateral side. An additional detent can be provided for mechanically locking the plug in an associated receptacle prior to electrical engagement of the contacts carried thereby.

It is an object of the present invention to produce an improved plug for use in high density patch systems in which the plug can be mated and unmated with closely spaced receptacles with a minimum of effort and wear 0n the plug.

It is another object of the present invention to produce a plug for high density pluggable patch systems in which the plug is molded plastics material and includes a locking lance on one side and resilient spn'ng member on the opposite side for biasing the locking lance t0- ward associated apertures in the receptacle.

It is yet another object of the present invention to produce a plug for high density pluggable patch systems in which the plug is capable of two step insertion, one step being a mechanical locking in the associated receptacle and the second step being a full mechanical and electrical latched position.

lt is a further object of the present invention to produce a plug for high density patch systems which plug may be readily and economically produced.

The means for accomplishing the foregoing objects and other advantages of the present invention will become apparent from the following detailed description taken with reference to the accompanying drawings.

BRIEF DESCRIPTION OF 'TI-IE DRAWINGS FIG. 1 is a perspective view of a high density patch system showing two multiple plugs according to the present invention, one inserted into a row of receptacles and a second positioned for insertion into another row of receptacles.

FIG. 2 is a longitudinal horizontal section taken along line 2 2 of FIG. 3;

FIG. 3 to FIG. 6 are side elevations, partly in section, showing steps during insertion of the subject plug into an associated receptacle;

FIG. 7 is an enlarged longitudinal vertical section, similar to FIG. 5, showing the subject plug partially inserted into the associated receptacle;

FIG. 8 is an enlarged longitudinal vertical section, similar to FIG. 6, showing the subject plug fully inserted into the associated receptacle;

FIG. 9 is an enlarged longitudinal vertical section similar to FIG. 7, showing an alternate embodiment of the subject plug partially inserted into an associated receptacle; and

FIG. 10 is an enlarged longitudinal vertical section showing the alternate embodiment of the subject plug fully inserted into the associated receptacle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Turning tirst to FIG. 1, the receptacle portion 10 of a high density patch system is formed by a plurality of individual receptacle units 12, 14, 16, 18, and 20. The individual receptacles are held together in a stacked array by conventional means (not shown) such as intermating projections and recesses. In the case shown, each of the receptacle units has six polarized cavities 22. The adjacent cavities 22 are in communication through shaped apertures 24. The cavities further include a passage 26 through the unit and a shoulder 28 formed in the passage. A male terminal contact 30 is mounted in passage 26 with locking lance 32 engaging the shoulder 28. The male terminal contact shown is of an elongated post configuration, generally rectangular in cross-section and provided with a tapered free end. The opposite end of the terminal is provided with a suitable configuration for receiving connecting conductors. The male terminal contact can have any de sired configuration suitable for electrically and mechanically engaging a mating Contact.

The subject plug is shown in FIG. l as two multiple or gang plug units 34, each comprising five individual plug members 36 connected by webs 38. Each plug member 36 includes a profiled unitary body 38 of plastics material having a longitudinal passage 40 for receiving a female receptacle contact 42. The forward end of the passage 40 has a shaped opening 44 which serves to guide the male terminal contact into the receptacle contact. A locking lance 46 projects from one longitudinal side of the plug member and a longitudinally extending spring 48 is formed on the opposite side of the plug. It is only necessary for at least one of the plug members in a gang unit to have a locking lance. On a third side of the plug there is an aperture 50, shown in FIG. 2.

The illustrated electrically conducting female receptacle contact 42 has a generally box-like receptacle configuration 52 provided with an open end 54 for receiving therein a male electrical terminal 30. The female receptacle contact can be fabricated from a single blank of stamped metal folded to form a generally channel shaped portion including a bottom wall 56 and two spaced parallel sidewalls 58, 60. The box-like receptacle configuration is formed by the channel por* tion and an elongated electrically conducting leaf spring contact portion 62 having a free end extending towards the open end 54 of the contact. The leaf spring 62 is integral with one sidewall of the channel and is folded about the sidewall to a position generally overlying the channel portion. The leaf spring may be provided with a projecting flange portion (not shown) which engages the opposite sidewall of the channel so that the leaf spring is fully supported by the channel portion. The elongated leaf spring contact 62 is preferably reversibly curved along its length. More specifically, a medial portion of the contact is first curved at an incline to converge generally towards the bottom of the wall 56 and the free end 64 of the contact is reversibly curved, with respect to the medial portion, to provide an outwardly flaring lip immediately adjacent the open end of the box-like configuration. The outwardly flared end provides a frontal profile at the entry which facilitates insertion of the tapered nose of the male contact. The reversedly curved spring forms an arcuate surface defining a narrow throat portion internally of the channel portion. In a similar fashion the bottom wall 56 may be optionally provided with a dimple 66 opposite the leaf spring Contact 62 to further restrict the relatively narrow throat portion.

The contact is further provided with an elongated helper spring portion 68 having a generally tapered configuration terminating at a free end which is pointed away from the open end 54. The helper spring 68 is integral with a sidewall of the channel and is folded about the sidewall such that it is in overlying relationship over the leaf spring contact 62. Accordingly, the helper spring is integral with one sidewall of the channel portion while the leaf spring contact is integral with the opposite sidewall of the channel portion.

The receptacle further includes an integral pair of clamping flanges 70 which are formed into opposed sidewalls portions and formed into a U-shaped before being subsequently curled toward one another to form a crimped barrel connection to a wire conductor 72 as shown. In this manner the receptacle may be securely electrically and mechanically connected to an electrically conducting insulated covered wire in a well known manner as taught by U.S. Pat. No. 2,791,755.

FIGS. 3 to 6 show steps during inserting the subject plug into an associated receptacle. FIGS. 7 and 8 show in detail what happens to the plug and the contacts during this insertion. Referring first to FIG. 3, the plug is brought into general alignment with the associated receptacle in a conventional manner. The plug is then inserted into the receptacle, as shown in FIG. 4. As soon as the locking lance 46 contacts the upper edge of the receptacle cavity 22 the plug is forced rotated counterclockwise, as shown in FIGS. 5 and 7. This rotational movement causes the spring 48 of the plug 36 to be compressed. As soon as the locking lance 46 clears the edge of the opening 24, the spring 48 will cause the plug to rotate in the reverse direction (clockwise) to fully seat as shown in FIGS. 6 and 8.

It will be noted, FIG. 7, that as the plug 36 is rotated counterclockwise, the male terminal contact 30 of the receptacle passes through the front opening 44 of the plug and opening 54 of the female receptacle contact 42 and between the leaf spring 62 with relatively low insertion force. The leaf spring 62 is partially compressed at during this stage of insertion to overcome the preloading of the spring by helper spring 68. When the plug is fully inserted, as shown in FIG. 8, the spring 48 will cause the plug to rotate in a clockwise direction, as shown, until the plug is fully seated. The rotational movement will bring the locking lance 46 into engagement with the aperture 50 at the top of the receptacle cavity 22. The leaf spring contact will be resiliently deflected by the rotation of the plug to store additional energy in the spring contact. The resilient energy will bias the spring contact into gripping relationship onto the male terminal. It is generally known that a stiffer spring contact will produce a greater gripping pressure on the male terminal which improves the electrical connection therewith and also impedes the unwarranted separation of the male terminal from the receptacle.

An alternate embodiment of the subject plug is shown in FIGS. 9 and 10, with like reference numerals identifying like parts. This plug member 74 has a detent projection 76 at the forward end 78 on the side opposite locking lance 46. Upon initial insertion of the plug member 74 into the receptacle 22, the detent projection 76 engages in shaped aperture 24a to lock the plug member in the receptacle with contacts 30 and 42 not in engagement. This allows for a patch system to be initially set up and subsequently electrically connected by simply fully inserting the plugs. The expensive switch over equipment normally employed to cut in new panels is thus obviated.

rl`he plug member 74 can be arranged in gang fashion similar to plug unit 34. When the plug member 74 is used in a gang, then it is only necessary for at least one of the plug members 74 to be provided with the detent means 74.

It will be seen from the above discussion and from the drawings that the subject of plug is readily adopted for high density applications in that a relatively small rotational movement of the plug is required to effect insertion and removal of the plug in a patch systeml The ganging of the plug is not limited to any number of individual units, except for practical limits in handling.

The present invention may be subject to many modifications and changes without departing from the spirit or essential characteristics thereof. The present embodiment should therefor be considered in all respects as merely illustrative and not restrictive.

What is claimed is:

l. A plug for use in high density patch systems having a receptacle portion with a plurality of closely spaced polarized cavities therein, said plug comprising:

a substantially rectangular plug member having a polarized transverse prole adapted to mate with said contacts being engaged, said spring means being deformed during insertion of said plug member into said cavity and biasing said locking lance into latching engagement with said cavity aperture when said plug member is fully inserted into said cavity. 7. A high density pluggable patch system according to claim 6 wherein said receptacle member comprises:

a plurality of receptacle units, each unit having a plurality of polarized cavities therein and means for joining said units together in an array. 8. A high density pluggable patch system according to claim 6 wherein said male terminal contact has a tapered pin and adapted to mate with said female recepcavities, a longitudinal passage through said plug, a locking lance extending laterally outwardly from one longitudinal side of said plug, a spring member extending in parallel spaced relation longitudinally along the opposite side of said plug with both ends 5 of said spring member integrally connected to said plug member, said spring being deformed during insertion of said plug member into said receptacle portion and biasing said locking lance into full latching engagement in said receptacle portion when said plug is fully inserted therein, and detent means at a forward end of said plug spaced from said locking lance whereby said plug is inserted in two steps with said detent means providing only mechanical latching in said receptacle portion. tacle Contact, locking lance means for fixedly mounting 2. A plug according to claim 1 wherein said plug is said terminal in said cavity, and means for connecting a unitary member of molded plastics material. conductors to said terminal.

3. A plug according to claim l wherein said plug fur- 9. A high density pluggable patch system according ther includes an aperture on a third side of said plug, to claim 6 wherein said plug member further includes and an aperture formed in a third side of said plug member,

a female socket contact mounted in said passage and and including locking lance means extending into said said female receptacle contact further includes lockaperture to fix said contact in said passage, means ing lance means adapted to engage said aperture of for fixing said contact to a conductor, and male tersaid plug member. minal contact receiving means. 10. A high density pluggable patch system according 4. A plug according to claim 1 further comprising: to claim 6 wherein said female receptacle contact ina plurality of said plugs having integral intermediate cludes:

webs between adjacent pairs of plugs, whereby said means for connecting said contact to an associated plugs are interconnected in gang fashion. conductor, and

5. A plug according to claim 4 wherein at least one 30 receptacle means comprising a channel shaped porplug of said gang of plugs has a locking lance. tion having a base pair and a pair of parallel spaced 6. A high density pluggable patch system comprising: sidewalls,

a receptacle member having a plurality of closely cantilever leaf spring means attached to one of said spaced polarized cavities, aperture means interconu sidewalls and overlying said channel shaped pornecting adjacent pairs of cavities; tion, said leaf spring converging towards said base a male terminal contact fixedly mounted in each said and being reversidly curved toward its free end,

cavity; a hump formed in said base opposite said leaf spring at least one substantially rectangular plug member defining a narrow throat therebetween, and

adapted to be inserted into any cavity of said recepa backup spring attached to the other of said sidetacle member, said plug member having a transwalls and overlying said leaf spring. verse profile mating with said polarized cavities, 11. A high density pluggable patch system according locking lance means extending from one side of to claim 6 further comprising a gang plug unit compris said plug, spring means extending in parallel ing: spaced relation longitudinally along an opposite a plurality of plug members and web means fixedly side of said plug with both ends of said spring interconnecting adjacent pairs of plug members in means integrally connected to said plug, a longitusaid unit, at least one plug member having a lockdinal passage through said plug, an aperture in said ing lance and at least one plug member having deplug leading to said passage and detent means on tent means at a forward end thereof for initially said plug member spaced forwardly of said locking mechanically locking said unit in an associated relance means; and ceptacle prior to mating of said contacts. female receptacle contact adapted to be mounted l2. A high density pluggable patch system according in said passage in said plug and to receive said male to claim 6 further comprising a gang plug unit compristerminal contact therein, said female contact ining a plurality of plug members and web means intercluding locking lance means extending into said apconnecting adjacent pairs of plug members. erture to fix said female contact in said passage, 13. A high density pluggable patch system according said detent means being adapted to first fixedly ento claim l2 wherein at least one plug of said gang plug gage said plug member in said receptacle in memember has a locking lance. chanical engagement without the electrical 

1. A plug for use in high density patch systems having a receptacle portion with a plurality of closely spaced polarized cavities therein, said plug comprising: a substantially rectangular plug member having a polarized transverse profile adapted to mate with said cavities, a longitudinal passage through said plug, a locking lance extending laterally outwardly from one longitudinal side of said plug, a spring member extending in parallel spaced relation longitudinally along the opposite side of said plug with both ends of said spring member integrally connected to said plug member, said spring being deformed during insertion of said plug member into said receptacle portion and biasing said locking lance into full latching engagement in said receptacle portion when said plug is fully inserted therein, and detent means at a forward end of said plug spaced from said locking lance whereby said plug is inserted in two steps with said detent means providing only mechanical latching in said receptacle portion.
 2. A plug according to claim 1 wherein said plug is a unitary member of molded plastics material.
 3. A plug according to claim 1 wherein said plug further includes an aperture on a third side of said plug, and a female socket contact mounted in said passage and including locking lance means extending into said aperture to fix said contact in said passage, means for fixing said contact to a conductor, and male terminal contact receiving means.
 4. A plug according tO claim 1 further comprising: a plurality of said plugs having integral intermediate webs between adjacent pairs of plugs, whereby said plugs are interconnected in gang fashion.
 5. A plug according to claim 4 wherein at least one plug of said gang of plugs has a locking lance.
 6. A high density pluggable patch system comprising: a receptacle member having a plurality of closely spaced polarized cavities, aperture means interconnecting adjacent pairs of cavities; a male terminal contact fixedly mounted in each said cavity; at least one substantially rectangular plug member adapted to be inserted into any cavity of said receptacle member, said plug member having a transverse profile mating with said polarized cavities, locking lance means extending from one side of said plug, spring means extending in parallel spaced relation longitudinally along an opposite side of said plug with both ends of said spring means integrally connected to said plug, a longitudinal passage through said plug, an aperture in said plug leading to said passage and detent means on said plug member spaced forwardly of said locking lance means; and a female receptacle contact adapted to be mounted in said passage in said plug and to receive said male terminal contact therein, said female contact including locking lance means extending into said aperture to fix said female contact in said passage, said detent means being adapted to first fixedly engage said plug member in said receptacle in mechanical engagement without the electrical contacts being engaged, said spring means being deformed during insertion of said plug member into said cavity and biasing said locking lance into latching engagement with said cavity aperture when said plug member is fully inserted into said cavity.
 7. A high density pluggable patch system according to claim 6 wherein said receptacle member comprises: a plurality of receptacle units, each unit having a plurality of polarized cavities therein and means for joining said units together in an array.
 8. A high density pluggable patch system according to claim 6 wherein said male terminal contact has a tapered pin and adapted to mate with said female receptacle contact, locking lance means for fixedly mounting said terminal in said cavity, and means for connecting conductors to said terminal.
 9. A high density pluggable patch system according to claim 6 wherein said plug member further includes an aperture formed in a third side of said plug member, and said female receptacle contact further includes locking lance means adapted to engage said aperture of said plug member.
 10. A high density pluggable patch system according to claim 6 wherein said female receptacle contact includes: means for connecting said contact to an associated conductor, and receptacle means comprising a channel shaped portion having a base pair and a pair of parallel spaced sidewalls, cantilever leaf spring means attached to one of said sidewalls and overlying said channel shaped portion, said leaf spring converging towards said base and being reversidly curved toward its free end, a hump formed in said base opposite said leaf spring defining a narrow throat therebetween, and a backup spring attached to the other of said sidewalls and overlying said leaf spring.
 11. A high density pluggable patch system according to claim 6 further comprising a gang plug unit comprising: a plurality of plug members and web means fixedly interconnecting adjacent pairs of plug members in said unit, at least one plug member having a locking lance and at least one plug member having detent means at a forward end thereof for initially mechanically locking said unit in an associated receptacle prior to mating of said contacts.
 12. A high density pluggable patch system according to claim 6 further comprising a gang plug unit comprising a plurality of plug members and web means interconnecting adjacent pairs of plug members.
 13. A high density pluggable patch system according to claim 12 wherein at least one plug of said gang plug member has a locking lance. 